Method of installing roof insulation on buildings



Feb. 1s, 1964 R. E. OLIVER 3,121,649

METHOD OF INSTALLING ROOF INSULATION ON BUILDINGS Filed July 28, 1961 l Uff/ .5' 0

J INVENTOR.

United States Patent O Filed July 28, 1961, Ser. N 127,640 11 Claims. (Cl. 156-71) This invention relates generally to insulation for buildings and more particularly to a novel and improved insulating blanket and a method of installing the blanket between the frame of the building and the outer surface thereof.

This invention is particularly suited to the construction of commercial metal buildings, but also has general application to all types of structures. ln order to promote a clear understanding of this invention, it is described and illustrated in conjunction with commercial type metal buildings to which it is well suited, but it should be understood that the invention is not limited to such structures.

Metal building structures for commercial purposes, such as warehouses, factories and the like are often constructed without finished inner walls or ceilings. The structure of such buildings includes only the metal framing, outer roof and wall surface panels, and insulation. ln the past it has been customary to erect the frame, stretch the insulation over the frame and then install the outer Wall and roof panels. With this construction it is necessary to erect scaffolding inside the building to enable workmen to reach and attempt to seal the joints in the vapor barrier after the insulation is installed. This method of construction results in an inferior structure since it is impossible to provide a non-leaking seal at the joints between the vapor barriers due to the interference of the framing.

The necessity of a continuous vapor barrier is well recognized since condensation within the insulation material causes rapid deterioration of the structure and greatly reduces the effectiveness of the insulation. Condensation occurs when the vapor laden air passing out of the building through the structure reaches the dew point. It is therefore essential that the vapor barrier be on the warm side of the insulation to prevent the penetration of the vapor to the point in the insulation where the dew point is reached and condensation occurs. Since insulated buildings other than refrigerator buildings are warm on the inside, the vapor barrier must be on the inside of the insulation. To be eliective the vapor barrier must provide a continuous non-leaking vapor seal.

A new and improved insulating blanket and method of installation according to this invention results in an improved building structure since a continuous vapor barrier is provided and the cost of construction is substantially reduced. The insulating blanket according to this invention is placed over the framing of the building so special fastening devices are not required, and the joints in the vapor barrier are completely sealed from the outside of the building, eliminating the requirement of special scaffolding. The resulting vapor barrier provides a continuous non-leaking vapor seal which prevents vapor penetration into the insulating material and as a result eliminates the problem of condensation.

It is an important object of this invention to provide a new and improved insulating blanket for building structures and the like.

It is another important object of this invention to provide a novel and improved method of installing insulation in building structures.

It is another important object of this invention to provide a novel and improved insulating blanket for buildings and method of installing such blanket.

It is another important object of this invention to pro- 3,121,649 Patented Feb. 18, 1964 vide a method for installing insulation having a continuous vapor barrier on a building between the frame members and the outer panels thereof.

It is another important object of this invention to provide a new and improved insulated metal building structure.

It is another object of this invention to provide a novel and improved insulating blanket including an insulating body, a vapor barrier on one side thereof with adhesive to provide a vapor-tight bond with the vapor barrier of adjacent blankets.

Further objects and advantages will appear from the following description and drawings wherein:

FIG. 1 is a fragmentary perspective View illustrating the preferred method of installing insulation incorporating this invention on the roof of a typical metal building;

FIG. 2 is a fragmentary exploded perspective view of the structure of the adhesive strips on the insulation blanket illustrating how they cooperate to seal the vapor barrier between adjacent blankets;

FG. 3 is a section of one form of an insulating blanket according to this invention;

FG. 4 is a section of a Second form of blanket incorporating this invention;

FIG. 5 is a fragmentary View of the blanket structure of FIG. 4- illustrating how the vapor barriers of adjacent blankets are sealed; and

FIG. 6 is a perspective view of a typical building having a roof frame illustrating the installation of insulation incorporating this invention between the building frame and roof proper.

Referring to FIGS. 1 through 3, an insulating blanket incorporating this invention is formed with a body 10 of fiberous material such as liber glass or rock wool with a vapor barrier l1 aiiixed to one side thereof. The vapor barrier may be formed of any suitable material such as aluminum foil, sheets of plastic lm formed of plastic such as vinyl, laminations of foil, scrim and kraft paper, or vapor barrier paper which is formed of laminations of kraft paper reinforced with sisal fibers. The principal requirement of the vapor barrier 1l is that it provides a substantially impervious wall to prevent penetration of vapor into the insulating body lll.

The insulation blankets are normally manufactured in long strips which are rolled for shipment. To install the blankets the rolls are cut to proper length and the blankets stretched over the frame as described below.

The vapor barrier 11 extends laterally beyond the body 1l? -along one side of the blanket to form a lip or flap 12. A pressure sensitive adhesive 13 is Ibonded to the upper surface of the lip 12 and is covered for shipment and storage by a ribbon or strip of separation paper 14. The adhesive 13 can be applied directly to the lip surface by any appropriate technique such as roller coating, spraying or the like or by means of pressure sensitive tape. Preferably the adhesive is carried on opposite sides of a suitable matrix such as thin paper which is interlaid between two `strips of separation paper forming a continuous tape. ln using such tape the separation paper is removed from one side of the adhesive carrier and the exposed adhesive is applied to the upper side of the lip 12 with the second separation paper 14 left adhered to the upper side of the adhesive for protection. The adhesive 13 and separation paper 14 are proportioned so that a portion along one edge of the paper carrier yis free of adhesive. Therefore, the separation paper 14 extends beyond the edge of the adhesive adjacent to the body 1li a short distance as indicated in FIGS. 2 and 3, so that the edge i6 of the separation paper adjacent to the body Ill is loose and can easily be gripped to start the removal of the separation paper. The pressure sensitive adhesive used can be chosen from many commercially available, preferably one having the properties of providing a permanent bond which is not affected by water or temperature variations and does not creep.

A similar second pressure sensitive adhesive strip 17 is bonded to the underside of .the vapor barrier 11 adjacent to the opposite edge of the blanket as illustrated in FIGS. 2 and 3. The structure of this adhesive and its application is the same as the adhesive applied to the lip 12. A second strip of separation paper 18 covers and protects the adhesive 17. Here again, the adhesive 17 and the separation paper 18 are proportioned so that the separation 118 projects beyond the edge of the adhesive which terminates at a line spaced from the outer edge of the Vapor barrier 11. This provides a loose edge` 19 on the separation paper 18 which can be eas-ily g-rasped to start the removal or stripping of the separation paper 18. ln applying the adhesive strips to the vapor barrier pressure, and in some cases heat, is used so that a tight bond results.

FIGS. 1 and 6 illustrate how the insulating blankets lare installed on the roofs of buildings. The building yframe 20 is iirst erected which includes purlins 15 extending between the ends of the building to constitute the roof supporting frame. A first blanket strip 21 is stretched across the purlins at one end of the building. The first course 4of outer surface material, such as sheet steel panels 22, is then installed over the rst blanket 21 and fastened to the purlins y15 in the usual manner. In the illustrated building corrugated metal roof panels are used for the outer surface and screws or similar fasteners 23 extend through the insulating blanket 21 into the purlins 15 to securely anchor the roof panels 22 in position. Vapor leakage does not occur around the fasteners 23 because the vapor barrier 11 is tightly pressed against the upper side of the purl-ins by the panels.

The rst course of roof panels 22 is positioned so that the edge of the blanket 21 projects beyond the edge o' the rst course of roof panels 22 as illustrated in FIGS. 1 and 6. A narrow rst course of roof panels, or a 'wide strip of insulating blanket, can be used to provide this projection or roof panels having the same width as the blankets but mounted to extend beyond the end of the building to provide an eave can be used to provide the required projection of the blanket 21 beyond the panel edges. rIhe blanket 21 is arranged so that the lip 12 is on the side projecting beyond the edges of the roof panels 22.

A second blanket strip 24 is then stretched across the purlins with the adhesive '17, covered by the separation paper 18, overlying the lip 12 of the iirst blanket 21. 1A simple weighted clamp 27 can be used at each end of the blanket to provide the tension to evenly stretch the blankets in position. The clamp 27 comprises two pieces of wood with bolts extending therethrough adjacent to the ends so that the ends of the blanket can be positioned between the pieces of wood and the bolts tightened to clamp the wood to the ends of the blanket. A weight such as a bag of sand 26 is suspended yfrom the clamp 27 to maintain a proper tension.

The Workman then reaches down between the bodies 10 of the two blankets 2K1 and 24 and grips the separation paper 14 on the lip 12. The separation paper 14 is pulled up between the abutting edges of the insulating bodies 10 of the two blankets 21and 24. It is easy to gripV the separation paper '14 because of the loose edge portion 16 which extends beyond the adhesive 13, and is located at the inner edge of strip 14 immediately below the abutting edges of the first blanket 21, which has been secured to the purlins 15, and the second blanket 24, which has been tightly stretched intoV place. After the separation paper 14 is started, the workman then grips the edge of the separation paper 18 and also pulls it up between thebodies 10 of the two blankets. The separation paper 18 is also easily grasped because its loose edge 19 is on the outer side of the strip `1S, immediately below the abutting edges of the blankets 21 and 24. The workman then -walks along the first course `of roof panels 22 pulling the two separation papers out between the insulation as illustrated in FIG. 1 with the separation paper 14 about a foot ahead of the separation paper 18. The separation paper 14 is stripped from the adhesive 13 before the paper 18 is pulled out because there is a tendency for the flap 12 to be pulled up slightly out of the plane of the barrier sheet 11 as the paper 14 separates from the adhesive 13. As the point of release of the paper 14 from the adhesive 13 is moved along, the llap 12 returns to its desired iat position within a distance less than about `a toot. The separation paper 18, on the other hand, rolls under the edge of the second blanket 2.4 and tends to pull downwardly on the adhesive 17 at the point of release, so that the two adhesive strips 13 and 17 are brought into contact substantially in the plane of the vapor barrier sheets 1v1.

When the adhesive 13 is initially exposed, it is aligned with, and can contact only, the separation paper 18. This paper, in accordance with the usual practice, is wax coated or similarly treated so that it adheres only lightly to the adhesive, and to avoid any premature sealing, the strip 18 is so treated or coated on both surfaces. When the separation strip 13 is pulled from the joint, however, the two adhesive strips 13 and 17 are aligned with each other and when they contact each other a rm cemented bond is provided between the lip of the blanket 21 and the left edge of the vapor barrier 11 of the blanket 24 and vapor cannot penetrate into the insulation. A light pressure on the edge of the blanket 24 insures proper bond between the two adhesive strips since a bond is established between two adhesive strips without pressure. A smooth bonded joint results from this method of installation since the rst blanket 21 is secured in position by the panels 22 and the second blanket 24 is retained smoothly in place by the weight 26 hanging on its ends. The second course of roof panels 22 is then installed over the second blanket 24 and the process repeated with a third blanket and so on until the roof is complete.

Because the adhesive is placed on the insulating blankets before the blankets are stretched across the purlins 15, a continuous bond is provided even in the area immediately adjacent to and on top of the purlins. The labor of installation is vastly reduced because it is not necessary toerect scaffolds underneath the roof after the roof is installed to apply the adhesive. No diflculty is encountered in properly positioning the consecutive blankets since the adhesive is covered while the blankets are stretched into place so that the blankets are easily moved into proper position. The adhesive is then uncovered and the bond established. The installation of the insulating blankets in this manner results in a continuous vapor barrier over the entire roof which prevents vapor from penetrating into the insulation and as a result eliminates condensation within the insulation.

When insulation is to be installed between the frame of the side wall of the building and the outer surface covering, the same method of application is used. The first blanket of insulation is positioned at the end of the building and the outer wall covering secured to the frame to hold the first blanket in place. The second blanket is then positioned adjacent to the first and the separation papers removed before the installation of the next course of wall panels. Here again a continuous vapor barrier is provided with no passages or leakage points so condensation within the installation is eliminated.

In FIGS. 4 and 5 another embodiment of this invention is illustrated. Blankets according to this embodiment are formed with lips or llaps 31 and 32 on each side of the insulating body 10. Adhesive 33 and separation papers 34 are bonded to thelower side of each of the lips 31 and 32, the separation papers extending inwardly beyond the adhesive so as to leave ree inner edges 35. In the installation of blankets incorporating this embodiment the lips 31 and 32 are folded up between the two bodies 1) of adjacent blankets as illustrated in FIG. so that the lips of the adjacent blankets abut each other The two separation papers 34 are then stripped away simultaneously, allowing contact between the adjacent adhesive strips 33 to establish the bond between the lips on adjacent blankets. Here again the blankets are stretched over the purlins l5 and bonded as the roof is installed as illustrated in FIG. 6.

Although preferred embodiments of this invention are illustrated, it will be realized that various modifications of the structural details may be made without departing from the mode of operation and the essence of the invention. Therefore, except insofar as they are claimed in the appended claims, structural details may be varied widely without modifying the mode of operation. Accordingly, the appended claims and not the aforesaid detailed description are determinative of the scope of the invention.

What is claimed is:

l. A method of installing insulation formed with an insulated body, a vapor barrier along one side thereof having a projecting lip extending from at least one longitudinal edge of said body, and a coating of adhesive on said lip covered by a removable protective covering on a building having frame members comprising stretching a first blanket over the outside of said frame with the vapor barrier side against said frame, stretching a second blanket adjacent said first blanket with its vapor barrier engaging said lip of said first blanket, and thereafter removing said covering and bonding the lip of said first blanket to the vapor barrier of said second blanket.

2. A method of installing insulation formed with an insulated body, a vapor barrier along one side thereof having a projecting lip extending from each longitudinal edge of said body on a building having frame members comprising coating at least one lip with an adhesive, covered by a removable protective covering, stretching a first blanket over said frame with the vapor barrier side on said frame, stretching a second blanket adjacent said first blanket with a lip thereof engaging said one lip of said first blanket, and thereafter removing said covering and bonding said one lip of said first blanket to a lip on said second blanket.

3. A method of installing insulation formed with an insulated body, a vapor barrier along one side thereof having a projecting lip extending from at least one longitudinal edge of said body on a building having frame members comprising coating said lip with an adhesive, covered by a removable protective covering, stretching a first blanket over said frame with the vapor barrier side on said frame, stretching a second blanket adjacent said first blanket with its vapor barrier engaging said lip of said first blanket, thereafter removing said covering and bonding the lip of said first blanket to the vapor barrier of said second blanket, and securing outer surface material on said framing over said blankets.

4. A method of installing insulation formed with an insulated body, a vapor barrier along one side thereof having a projecting lip extending from one longitudinal edge of said body on a building having frame members comprising coating said lip with an adhesive, covered by a removable protective covering, stretching a first blanket over said frame with the vapor barrier side on said frame, securing outer surface material to said frame over said blanket with the edge havinU said lip exposed, stretching a second blanket adjacent said first blanket with its vapor barrier engaging said lip of said first blanket, there after removing said covering and bonding the lip of said first blanket to the vapor barrier of said second blanket, and thereafter securing outer surface material t0 said framing over said second blanket.

5. A method of installing insulation formed with an insulated body, a vapor barrier along one side thereof havingan adhesive coated lip covered with separation ribbon extending from one longitudinal edge of said body on a building having frame members comprising stretching a first blanket over said frame with the vapor barrier side against said frame, securing Outer surface material to said frame over said blanket with said lip exposed, stretching a second blanket adjacent said first blanket with its vapor barrier abutting said lip, thereafter removing said separation ribbon and bonding the lip of said first blanket to the vapor barrier of said second blanket, and thereafter securing outer surface material to said framing over said second blanket.

6. A method of installing insulation blankets formed with an insulated body, a vapor barrier along one side thereof having an adhesive coated lip covered with separation ribbon extending from one longitudinal edge of said body on a building having frame members comprising stretching a first blanket over said frame with the vapor barrier side on said frame, securing surface material to said frame over said blanket with the edge having said lip exposed, stretching a second blanket adjacent said first blanket overlying said lip, thereafter removing said separation ribbon and bonding the lip of said first blanket to the vapor barrier of said second blanket, and thereafter securing surface material to said framing over said second blanket.

7. A method of installing insulation blankets formed with an insulated body, a vapor barrier along one side thereof having a projecting lip extending from one longitudinal edge, and first and second strips of adhesive covered with separation ribbon along said lip and the Opposite edge of said vapor barrier respectively on a building having frame members comprising stretching a first blanket over said frame with the vapor barrier side on said frame, securing surface material to said frame over said blanket with the edge having said lip exposed, stretching a second blanket adjacent said first blanket with said second strip of said second blanket overlying said first strip of said first blanket, thereafter removing said separation ribbon and bonding the lip of said first blanket to the vapor barrier of said second blanket, and thereafter securing surface material to said framing over said second blanket.

8. A method of installing insulation on a building having a roof frame comprising forming blankets with an insulating body and a vapor barrier on at least one side thereof having a lip projecting beyond one edge, bonding first and second adhesive strips to said lip and the opposite edge of said vapor barrier respectively, covering said adhesive with separation ribbon having a width greater than the width of said strips leaving loose edges adjacent the edges of said body, stretching a first blanket over said frame with the vapor barrier thereof against said frame, attaching roof material to said frame over said first blanket with said lip exposed, stretching a second blanket over said frame with its vapor barrier against said frame and its second strip abutting the rst strip of said first blanket, gripping the loose edges of the separation ribbons on said abutting strips and pulling them out between the insulation bodies of said first and second blankets, and thereafter attaching roof material to said frame over said second blanket.

9. A method of installing insulation on a building having a frame comprising forming blankets with an insulating body and a vapor barrier on one side thereof having a lip projecting beyond one edge, bonding first and second adhesive strips to the upper side of said lip and the lower opposite edge of said vapor barrier respectively, covering said adhesive with separation ribbons having a width greater than the width of said strips leaving loose edges, stretching a first blanket over said frame with the vapor barrier thereof against said frame, attaching surface material to said frame over said first blanket with said lip exposed, stretching a second blanket over said frame with its vapor barrier against said frame and its second strip overlying the first strip of said first blanket, gripping the loose edges of the separation ribbon on said overlying strips and pulling them out between the insuiation bodies of said first and second blankets,

7 and thereafter attaching surface material to said frame over said second blanket.

10. A method of installing insulation on a building having a frame comprising forming blankets with an insulating body and a vapor barrier on one side thereof having a lip projecting beyond one edge, bonding iirst and second adhesive strips to the upper side of said lip and the lower opposite edge of said vapor barrier respectively, covering said adhesive with separation ribbonsV having a width greater than the width of said strips leaving loose edges, stretching a first blanket over said frame with the vapor barrier thereof against said frame, attaching surface material to said frame over said first blanket with said lip exposed, stretching a second blanket over said frame with its vapor barrier against said frame and its second strip overlying the first strip of said iirst blanket, gripping the loose edge of the separation ribbon on said first strip of said first blanket and pulling it out between the insulation bodies of said first and second blankets, thereafter gripping the loose edge of the separation ribbon on said second strip of said second blanket and pulling it out between the insulation bodies of said iirst and second blankets, and thereafter attaching surface material to said frame over said second blanket.

11. A method of installing insulation blankets on a building having frame members, each of said blankets comprising an elongated insulating body and a vapor barrier covering one side of said body, said vapor barrier projecting beyond one longitudinal edge of said body forming an extended lip sealing portion and terminating substantially flush with the other longitudinal edge of said body providing adjacent said other longitudinal edge a second sealing portion, at least one of said sealing portions having a longitudinal extending adhesive strip secured thereto and covered with a removable protective covering, the method comprising stretching a first one of said blankets over the outside of said frame members with the vapor barrier side facing said frame members, stretching a second one of said blankets adjacent said first ianket with the said second sealing portion of said second blanket overlying the lip sealing portion of said first blanket and thereafter removing said protective covering and bonding the lip sealing portion of said first blanket to the second sealing portion of the second blanket.

References Cited in the file of this patent UNITED STATES PATENTS 2,007,403 Macau July 9, 1935 2,300,488 Cuno Nov. 3, 1942 2,491,281 Rowe Dec. 13, 1949 2,717,848 aye Sept. 13, 1955 2,776,231 Brown Jan. 1, 1957 2,799,232 iaeger July 16, 1957 2,871,601 Warnow Feb. 3, 1959 2,913,104 Parker Nov. 17, 1959 3,003,288 Leibrook et al Oct. 10, 1961 3,003,289 Leibrook et al Oct. 10, 1961 

1. A METHOD OF INSTALLING INSULATION FORMED WITH AN INSULATED BODY, A VAPOR BARRIER ALONG ONE SIDE THEREOF HAVING A PROJECTING LIP EXTENDING FROM AT LEAST ONE LONGITUDINAL EDGE OF SAID BODY, AND A COATING OF ADHESIVE ON SAID LIP COVERED BY A REMOVABLE PROTECTIVE COVERING ON A BUILDING HAVING FRAME MEMBERS COMPRISING STRETCHING A FIRST BLANKET OVER THE OUTSIDE OF SAID FRAME WITH THE VAPOR 